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Recommendations for Implementing the Strategic Initiative INDUSTRIE 4.0 Final Report of the Industrie 4.0 Working Group

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Recommendations for Implementing the Strategic Initiative INDUSTRIE 4.0 Final Report of the Industrie 4.0 Working Group Securing the future of German manufacturing industry Recommendations for implementing the strategic initiative INDUSTRIE 4.0 Final report of the Industrie 4.0 Working Group April 2013 Imprint Authors Contact details / Marketing Communication Promoters Group of the Industry-Science Office of the Industry-Science Research Alliance Research Alliance: beim Stifterverband für die Deutsche Wissenschaft Prof. Dr. Henning Kagermann Ulrike Findeklee, M.A. National Academy of Science and Engineering [email protected] (Spokesperson of the Promoters Group) forschungsunion.de Prof. Dr. Wolfgang Wahlster German Research Center for Artificial Intelligence Secretariat of the Platform Industrie 4.0 Dr. Johannes Helbig Lyoner Straße 9 Deutsche Post AG 60528 Frankfurt/Main [email protected] acatech – National Academy of Science and Engineering plattform-i40.de Editorial staff Ariane Hellinger, M.A. Veronika Stumpf, M.A. With the assistance of: Christian Kobsda, B.A. acatech – National Academy of Science and Engineering Publication date: April 2013 Copy editing Linda Treugut, M.A. acatech – National Academy of Science and Engineering English translation Joaquín Blasco Dr. Helen Galloway Layout and typesetting HEILMEYERUNDSERNAU GESTALTUNG © Copyright reserved by the authors. All rights reserved. This work heilmeyerundsernau.com and all its parts are protected by copyright. Any use not explicitly permitted by copyright law shall require the written consent of the authors. Failure to obtain this consent may result in legal action. Graphics This applies in particular to reproductions, translations, microfilming isotype.com and storage in electronic systems. The authors are not liable for the HEILMEYERUNDSERNAU GESTALTUNG accuracy of manufacturers’ data. Contents Contents Executive summary ...................................................................................................................................................04 Working group members | Authors | Technical experts .......................................................................................08 1 Introduction .......................................................................................................................................................12 2 The vision: Industrie 4.0 as part of a smart, networked world ............................................................ 18 2.1 Shaping the vision of Industrie 4.0 ................................................................................................... 19 2.2 What will the future look like under Industrie 4.0? .............................................................................. 20 2.3 Novel business opportunities and models ......................................................................................... 22 2.4 New social infrastructures in the workplace ...................................................................................... 23 2.5 Novel service-based, real-time enabled CPS platforms ...................................................................... 24 2.6 The road to Industrie 4.0 ................................................................................................................ 25 Example application 1 Reducing the energy consumed by a vehicle body assembly line while it is not in use ................................27 3 The dual strategy: becoming a leading market and supplier ............................................................. 28 3.1 Leading supplier strategy ............................................................................................................... 29 3.2 Leading market strategy ................................................................................................................. 29 3.3 The dual strategy and its key features .............................................................................................. 30 Example application 2 End-to-end system engineering across the entire value chain ..........................................................................33 4 Research requirements ...................................................................................................................... 34 5 Priority areas for action ...................................................................................................................... 38 5.1 Standardisation and open standards for a reference architecture ........................................................ 39 5.2 Managing complex systems ............................................................................................................ 42 5.3 Delivering a comprehensive broadband infrastructure for industry ....................................................... 45 5.4 Safety and security as critical factors for the success of Industrie 4.0 .................................................. 46 5.5 Work organisation and work design in the digital industrial age ........................................................... 52 5.6 Training and continuing professional development for Industrie 4.0 ...................................................... 55 5.7 Regulatory framework .................................................................................................................... 58 5.8 Resource efficiency ....................................................................................................................... 62 Example application 3 Supporting custom manufacturing: an example of how an individual customer’s requirements can be met ....................................................................................................................64 2 Industrie 4.0 Contents Contents Example application 4 Telepresence ..............................................................................................................................................................65 6 How does Germany compare with the rest of the world? .................................................................. 66 Example application 5 Sudden change of supplier during production due to a crisis beyond the manufacturer’s control .............73 7 Outlook ...............................................................................................................................................74 Background: The strategic initiative Industrie 4.0 ...................................................................................... 76 Industrie 4.0 3 Executive summary Executive summary Executive summary Germany has one of the most competitive manufac- enable and require end-to-end engineering across the turing industries in the world and is a global leader in entire value chain. the manufacturing equipment sector. This is in no small measure due to Germany’s specialisation in re- Industrie 4.0 holds huge potential. Smart factories allow search, development and production of innovative individual customer requirements to be met and mean manufacturing technologies and the management of that even one-off items can be manufactured profitably. complex industrial processes. Germany’s strong ma- In Industrie 4.0, dynamic business and engineering chinery and plant manufacturing industry, its globally processes enable last-minute changes to production significant level of IT competences and its know-how and deliver the ability to respond flexibly to disruptions in embedded systems and automation engineering and failures on behalf of suppliers, for example. End-to- mean that it is extremely well placed to develop its end transparency is provided over the manufacturing position as a leader in the manufacturing engineering process, facilitating optimised decision-making. In- industry. Germany is thus uniquely positioned to tap dustrie 4.0 will also result in new ways of creating val- into the potential of a new type of industrialisation: ue and novel business models. In particular, it will pro- Industrie 4.0. vide start-ups and small businesses with the opportunity to develop and provide downstream services. The first three industrial revolutions came about as a result of mechanisation, electricity and IT. Now, the in- In addition, Industrie 4.0 will address and solve some troduction of the Internet of Things and Services into of the challenges facing the world today such as the manufacturing environment is ushering in a fourth resource and energy efficiency, urban production and industrial revolution. In the future, businesses will es- demographic change. Industrie 4.0 enables continu- tablish global networks that incorporate their machin- ous resource productivity and efficiency gains to be ery, warehousing systems and production facilities in delivered across the entire value network. It allows the shape of Cyber-Physical Systems (CPS). In the work to be organised in a way that takes demograph- manufacturing environment, these Cyber-Physical ic change and social factors into account. Smart as- Systems comprise smart machines, storage systems sistance systems release workers from having to per- and production facilities capable of autonomously ex- form routine tasks, enabling them to focus on creative, changing information, triggering actions and control- value-added activities. In view of the impending short- ling each other independently. This facilitates funda- age of skilled workers, this will allow older workers to mental improvements to the industrial processes extend their working lives and remain productive for involved in manufacturing, engineering, material us- longer. Flexible
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